Jotdttbated mateblal and method of manttbiacttibnig the same



E. J; GUAY a, mnunuan run-sun. AND METHOD OF MANUFACTURING ran sun I 7Filed August 15. 1921 fm/e/7o/; [ml/e J 600g, by His flttorney.

- 20 OIB 111 US$- Patented May 4,

UNITED S.

r T s' P ENT OFFICE.

, m ne .1. GUAY, or LYNN, massncnusii'rrs; ASSIGNOR {DO-GENERAL anaemiccoit-- rm, A companion or ivnwvoax.

'nvnum'rnn aim'iini'non or manurac'runina'rnn saint.

Applicationflled August 15, 1921.; Serial No; 492',824.

To-allwhom itmay concern." 1 Be it known that I, Em J. GUAY, a citizenof the United States, residing at Lynn, in the county of Essex, State ofMassachu- 5 setts, have invented certain new and useful Improvements inIndurated Materials and Methods. of Manufacturing the Game, of which thefollowing is a specification.

V The present invention relates to indu- 10 rated material made fromspinnable textile materialv and an adhesive binder and to themanufacture of such material.

The object ofthe invention is to pro vide an improved indurated materialof this type, and an improved method of manufacturing the same wherebythere is obtained an indurated product possessing physical propertieswhich make it superior to similar roducts manufactured by methodsheret0- Particularly is this true. where the indurated material 18 to beput to uses requiring great strength coupled with elasticit that is,ability to eflect without brea 'ng. 'One extensive a plication. for in-2 -durated materal of this dharacter and an 2 application 'where greatstrength coupled with elasticity are ofhighest importance isfor'gearwheels, such gear wheels being known as non-metallic or noiseless gear.

80 wheels. The life ofnon-metallic or noiseless gear wheels made ofindur'ated material ormed'from spinnable textile material and anadhesivebinder is directly proportional. to the's h of the indurated materialand its ability to deflect under load, (other things being-equal) and bytests I have found that indurated material made by my improved method ismuch stronger and more flexible than similar material made b other 40methods in-commo'nuse. As a result gear wheels-manufactured ffromindurated ma j terial made in accordance with my invention will have alife substantially longer than gear wheels manufactured from similarmaterial made by other known methods.

According to my method I take. pieces of spinnable textile material comrising hard I, twisted threads such as a suita le" grade of.

canvas or cotton duck for example, and stack them one on another with athin layer or covering of adhesive binder in dry formbetweensuccessivelpieces. When-the textile, material is-in the form of wovenfabric, the pieces are stacked preferabl with the'wa of successivepieces at-a rig t angle to see .and intensity on the 7 other, since suchcloth is stronger in .one direction than. the other and by stacking bothdirections results. --Accord1ng to one embodiment of my invention, informing a stack I take a. supportin plate which may be made of metasprin lea. .thin layer of powdered adhesive over its surface, place apiece of fabric thereon, sprinkle a thin layer ofpowdered adhesive onits upper surface, place another piece of fabric on the first piece withits warp at a right angle to the warp ofthe first piece, sprinkle a thinlayer of powdered adhesive on it and continue 1n this manner until astack is formed having the desired number of layers. A metal platesimilar to the bottom plate may be then them in this manner a massequally strong in placed on the top. of the stack after which the entirebuilt-up structure is placed in a press and subjected to heavy pressure.I

' mayuse an hydraulic press and have found ressure of from 600 lbs. persq. inch to 900 be. per sq. inch satisfactory. While the stack is heldunder ressure, and preferably While it is still in-t e press, I subjectit to heat 'tofuse the-adhesive and causeit to permeate the layers offabric. The extent of the heating will depend-upcharacter the adhesivematerial and can be -readily determined by experiinent. After theheatinis completed, the

stack is cooled while stil held under pressure after which it is removedfrom the press. I then have-anpindurated lateor board formed ofsuccessive layers 0 woven fabric held under heavy pressure bythe ad-'hesive. As an adhesive I preferably use powdered bakelite, I may useother adhesives which can be obtained in powdered form.- I

In an i 'durated' materi 'or powdered shellac, but

a al of this character it is the textile material held :underhigh;

c m] 5 a binder. 1 The strength and toughnessis due to the many fibresheld in-close contact with each} other: and. the

wherein I use adhesive in wderedflform and place the textile materialunder hiih ente. v to any great extent between the cotplression.whi'clrflle'nds the strength and ness to it, the adhesive acting only as1 4 greater the'number ofr' 4 fibres thus held the greater the strengthand toughness. 'j By. .the method just describedtonfibres andparticularly between the fibres 4 which form the individual threads,such threads being in substance a bundle of fibres.

In the manufacture of indurated materialof this character, by methodsheretofore in use, the adhesive has, so far as I am aware, been appliedto the fabric in liquid form,

the adhesive being carried by a suitable sol vent, and then dried todrive off the solvent. I have found that by thismethod the adhesive iscarried in around the fibres to a great extent so that when sheets whichhave been impregnated with a liquid adhesive and the surfaces of thethreads, as is the case when the adhesive is'used in powderedform, andthe compressing ofthe built up stack prior to any heating orimpregnating ofthe textile material with the adhesive as being manner ofcarrying out my method lShBd material.

important features of my invention. It will be noted that prior to theheating operation, the dry adhesive is located primarily on the surfacesof the individual threads, and when this dry adhesive, such as bakelite,becomes liquefied by the heat, it distributes itself around among thethreads to fasten them together.- Since at the time, however, thethreads are held under compression, the fused adhesive does not saturateall the-individual fibres as is the case when a solvent is used, butenters more around the bundles of fibres, thus making a much strongerproduct.

. In the accompanying drawing which is illustrative ofmy invention, Fig.I is a .top plan view partly broken away showin on;

v 1g. is a side elevation of a stack of sheets prior to beingcompressed; Fig. 3 shows the same stack of sheets between the jaws of anhydraulic press and afterthey havebeen com-- pressed, and Fig. 4 shows ablock of the fin-' Referring to the drawing, 5 indicates the lower plateand 6 the upper-plate between which area number .of sheets of wovenfabric 7, there being a thin. covering of adhesive between each of thesheets.

I have made a most satisfactory product from heavy cotton duck andpowdered bakelite, and I shall now specifically describe my method whenutilizing these materials.

I first place the plate 5, which-is preferably a metal plate,- upon asuitable support and cover it with a very thin coating of powderedbakelite. This may be sprinkled on by. hand or dusted on .by a suitablemachine. Ithen placea sheet of cotton duck on plate {rafter which a thincoating of the powdered bakelite is sprinkled on the upper surface ofthe sheet; Following this I place a second sheet of duck on the firstone, with the warp at a ri ht angle to that of the first sheet,and*sprin le a thin coating 'of powdered bakelite on it. This'isrepeated until a stack of the desired height is obtained. Wit-h heavyduck I have found that about fifty sheetsarerequired to providesuflicient' material for a finished product .one inch thick. I

: After the sheets. 7 have been stacked in place I put the top plate 6onthe uppermostlone. This-plate may be of the same character as-theplate 5. The stack of sheets,

held between plates 5 and 6'are then placed between the jaws ofanhydraulic press Whlch are indicated diagrammatically at 8 and 9. Thesejaws are preferably hollow and. are provided with pipes 10- leading tothe interior of them so that steam forheating purposes and water forcooling purposes may be admitted. The place the stack of material. undera pressure of about 700 lbs. per brings the fibres of the material intovery close contact. Steam is then admitted to the jaws 8 and 9 of thepress for the purpose of' fusing the bakelite and causing it squareinch. This 1 press is operated to to stick thesheets of fabric together.The

heating is preferably performed -gradually.' I may first admit lowpressure steam of a pressure of about 10 to 20 lbs. (temperature about240 F.)'- for about ten minutes. The temperature may 'then be raised bytaking steam of 40 to 50 lbs. pressure (temperature 285 to 295 F.)' th1stemperature being maintained for from 10 to'15 minutes. I

then admit steam of about 110 lbs pressure.

(temperature about 345 F.) maintaining this for about two hours or moredepending on the thickness of 'the stack of sheets. During thecompression and heating excess of bakelite is squeezed out around theedges of the stack of sheets. The powdered bakelite is dusted onsparingly 'so there will be little excess the approxlm'a'te amount touse being readily determined by experiment.

After the heating process is completed the steam is shut off and coolingwater admitted through the pipes 10 to cool the material.

The pressure is maintained during the cooling and when the desired lowtemperature is reached the hydraulic press is opened and the finishedproduct'removed. It-is then ready to be used for any urpose for which itmay be found a'ppllca 'the'making' of gear wheels. A characteristicfeature of my invention Is, for example,

and one-which I consider of greatimportance is that of having theadhesive material on the surfaces of the hard twisted threads asdistinguished from having it distributed throughout the fibers of thethreads as 'in the case when the sheets are treated by the ordinaryso-termed wet method. As to this aspectof my invention, it is notnecessary suitable manner, the essential thing 40 stackingthem one onanother A coating of the adhesive in dry /form between that the adhesivematerial be applied to the textile material in the.form of a powder..

It may be applied equallywell'to the surface of the textile material, inany ggher 1 that the adhesive binder be located-primarily on thesurfacesof thethreads. It will be understood that in the claims whereinI call for dry adhesive binder on the surfaces of. 1 the textilematerial, I mean that t-he adhesive binder is primarily on the surfacesas distinguished from being "distributed throughout the fibers of theindividual threads.

15 I preferably make the sheets in squares as this is a convenient shapeand the metal plates 5 and i-are made somewhat greater in dimensions soas to overlapthe'm on all sides. This serves to take care of the widen-2 ing out of the sheets when placed under compression and. also to holdany bakelite which is squeezed outduring the process.

My improved niethod, in addition to producing a liiate'rial havingproperties su erior to those of. s1m1lar materials made y other methodspossesses the further .advantages when carried out. with. the use of anbinder in powdered form that itadhesive can be carried out at a lowercost because it saves the use of a solvent for'the adhesive material, issimple to perform, and requires no expensive equipment. 1

What I- laim as new and desire tosecure nable textile woven fabric madefrom hard, twisted threads, and an. adhesive binder, which comprisestaking pieces of fabric and with a surface them, subjecting the stack topressure, and then heating the stack to fuse the adhesive binder.

The method of manufacturing a ma- .terial of the character describedfrom spinnable textile woven fabric formed from hard,

twisted threads, and an adhesive .binder, which co prises takingv piecesof fabric and v stacking them one on another with av surfaeecoating ofthe adhesivein dry form he- .tweenjthem, the warp of successive sheetsbeing laid at a right angle to each other, subing t Letters Patent ofthe United States, is The method of manufacturing a ma-c terial of, thecharacter described from spin-v vidual. fibers o pressed into directcontact with each other.

jecting the stack to pressure, and heatng the stack to fuse the adhesiveb' He durated mate ial from spinnable textile woven fabric 'made fromhard, twisted threads, and phenolic condensation productv whichcomprises taking pieces of fabric and stacking them one on another witha surface" coating of the "adhesive in dry form between them subjectingthe stack to pressure, heat he stack while fheldunder pressure to fusethe adhesive binder, the resulting product while still under pres. sure.L

-5. The method of manufacturing an article of the character describedfrom a'textile' material comprising hard, twisted threads,

and an' adhesive binder, which com rises fo ing a stack from piecesof-the m erial with dry adhesive binder located,primarily on thesurfaces of the pieces, subjecting the r 3. The methodof manufacturingahainw.

and then cooling stack 'to pressure, and then heating the stack whileunder ressure to fuse the adhesive binder where y in thefinished'article the fibres of the vhard, twisted, textile material aremaintained in' direct engagement with each other by the surroundingadhesive material.

6. An indurated article comprising a plurality of'pieces of textilematerial of hard twisted threads, said pieces being in close proximityone with another, and a' hard dry binding material extending through theinsaid threads to other and olds the indithe. threads closely com;

In witness whereof, I have hereunto set my. hand this lg 2thday ofAugust,"1921,

EMILE J. AY.

'terstices between the threads without s aturating the threads, whichbindin material binds

